Table of Contents

Table of Contents……………………………………………………………………………………………………………………………………………………………………………………….……….. 1

1.0 Introduction & Objectives …………………………………………………….. ……………………………………………………………………….………………………………………… 3

1.1 Preface ……………………………………………………………………………………………………………………………………………………………………………………….……….. 4

1.2 Structure of the SOP……………………………………………………………………………………………………………………………………………………………………….………… 5
1.3 Objectives…………………………………………………………………………………………………………………………………………………………………………………………….. 5
1.4 Glossary of the Terms Used………………………………………………………………………………………………………………………………………………………………………… 6
1.5 Process Map Symbols…………………………………………………………………………………………………………………………………………………………………………….…. 7
1.6 Version Control History………………………………………………………………………………………………………………………………………………………………………….…… 7
1.7 Periodicity of Review…………………………………………………………………………………………………………………………………………………………………………….…… 7
1.8 Change Control………………………………………………………………………………………………………………………………………………………………………………….……. 7

2.0 Stadandard Operating Procedure.………………………………………………………………………………………………………………………………………………………….…………….. 8

2.1 Development Process…………………………………………………………………………………………………………………………………………………………………………….….. 9

2.2 Pre-production Process……………………………………………………………………………………………………………………………………………………………………………… 10
2.3 Bulk Production Process……………………...………………………………………………………………………..……………………………………………………………………………. 15

3.0 Process Maps…………………………………………………………………………………………………………………………….………………………………………………………….………….…. 17

3.1 Development Process…………………………………………………………………………………………………………………………………………………………………………….….. 18

3.2 Pre-production Process……………………………………………………………………………………………………………………………………………………………………………… 19
3.3 Bulk Production Process…………………………………………….………………………………………………..……………………………………………………………………………. 26

4.0 Formats/Documents………………………………………………………………………………………………………………………………………………………………………………..…………… 30

TEC001 Style Review Meeting Minutes………………...………................................................................................................................................................................................................ 31

TEC002 Style Changeover Plan............................................................................................................................................................................................................................................... 32
TEC003 Input Control Chart Summary (Next 45 Days Input)…............................................................................................................................................................................................... 33
TEC004 Pilot Run/PP Meeting Schedule for Technical Department………………………………………………………………………………………………………………...……………………. 34
TEC005 Pattern Amendment Sheet ……………………………………………………………………………………………………………………….………………….………..……………………. 36
TEC006 Pilot Run Cutting Requisition……………................................................................................................................................................................................................................... 37
TEC007 New Styles (Pilot/ 1st Bulk) Before Cutting Layer Check List..................................................................................................................................................................................... 38
TEC008 Trims Requisition Slip ................................................................................................................................................................................................................................................ 39
TEC009 Final Pattern Measurement........................................................................................................................................................................................................................................ 40
TEC010 Wash Measurement Check Form............................................................................................................................................................................................................................... 41

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 Table of Contents

4.0 Formats/Documents (Continued….)

TEC010A Non Wash Measurement Check Form……………………………………………………………………………………………………………………………………………………………. 42
TEC011 Wet/Dry/Wrinkle Free Sample Requisition Form...................................................................................................................................................................................................... 43
TEC012 Monthly Style Changeover Responsible Personnel Report…….............................................................................................................................................................................. 44
TEC013 Sewing Operation Bulleting & Thread Consumption Form....................................................................................................................................................................................... 45
TEC014 Pre Production Review Summary…………………………………………………………………………………………………………………………………………………………………. 47
Index…………………………………………………………………………………………………………………………………………………………………………….. 47
Sheet -1 PP Review Summary……………………………………………………………………………………………………………………………………………………….. 48
Annexure - 1 Production Data & TNA…………………………………………………………………………………………………………………………………………………….. 52
Annexure - 2 Sewing Operation Analysis (Operation Control Chart) ………………………………………………………………………………………………………………….. 53
Annexure – 2A Finishing Operation Analysis……………………………………………………………………………………………………………………………………………….. 55
Annexure - 3 Fabric & Trims BOM…………………………………………………………………………………………………………………………………………………………. 56
Annexure - 4 Process Control (Process Checklist) ……………………………………………………………………………………………………………………………………… 59
Annexure - 5 Approvals (Approvals from Merch/Customer)…………………………………………………………………………………………………………………………… 61
Annexure - 6 Photo Gallery…………………………………………………………………………………………………………………………………………………………………. 62
Annexure - 7 Style Control Chart…………………………………………………………………………………………………………………………………………………………… 63
Style Specific Changeover Responsible Personnel Report…………………………………………………………………………………………………………… 64
TEC015 Style Changeover Layout......................................................................................................................................................................................................................................... 65
TEC016 Line Feeding Plan..................................................................................................................................................................................................................................................... 66
TEC017 Cutter Must………………………………………………………………………………………………………………………………………………………………………………………..…. 67
TEC018 Pilot Review Report……………………………………………………………………………………………………………………………………………..………………………………..…. 68
TEC019 Operation Specification Sheet.................................................................................................................................................................................................................................. 70
TEC020 Pilot Line Manpower Clarification Chart………………………..................................................................................................................................................................................... 71

5.0 Key Performance Indicators (KPIs) and Cockpit Charts…………………………………………………………………………………………………………………………….………… 72

5.1 Technical Process KPI Template……………………………………………………………………………………………………………………………………………………...……......... 73

5.2 Technical Process Charts (Specimen)..…………………….……………………………………………………………….………………………………………………………………..….
5.2.1 Technical Process Cockpit Chart (Specimen)………………………..……………………………………………………………………...…………………………………...… 74
5.2.2 Technical Process Data (Specimen)…………………………………………………………………………………………………………………………………………….…… 75

6.0 Audit Checklist………………………………………………………………………………………………………………………………………………………………………………..……………….… 76

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 Section 1:
Introduction and Objectives

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 1. Introduction

1.1 Preface

1.1.1 It is of paramount important that business processes in an organisation is run in an consistent manner in order to achieve the desired vision, mission, goals and
objectives of an organisation since in consistent processes will derive in consistent results irrespective of how good the inputs to the processes are.

1.1.2 Objective of developing and maintaining Standard Operating Processes (SOPs) are to ensure that any person responsible to run either a part or the entire process
have absolute clarity as to how the process must be run in order to achieve the desired results.

1.1.3 Further SOPs will enable standardization of the way each Strategic Business Unit (SBUs) is run, hence enabling the comparison of results and achievements
between the same. SOPs will enable an organisation to be process driven rather than person driven, which will ensure consistency in the results achieved in terms
of productivity, cost, quality, delivery, safety and morale.

1.1.4 All CEOs/COOs/HOOs will be responsible for adherence to standard operating procedures (SOPs) and will be closely monitored by the country manager of Epic
Group, Bangladesh for compliances with this SOP at these Facilities.

1.1.5 Issues regarding interpretation and modification of this SOP will be decided by Managing Director of Epic Group. Any amendment to this SOP should be approved
by Managing Director of Epic Group.

1.1.6 This SOP is applicable to all the facilities in the EPIC Group, irrespective of the geographical location.

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1.2 Structure of the SOP
SOP consists of five key areas to be adhered and followed to ensure that the desired result to be achieved.
Section 1 : Introduction & Objectives

Section 2 : Standard Operating Procedures

2.1 – Development Process

2.2 – Pre Production Process
2.3 – Bulk Production Process

Section 3 : Process Maps

3.1 – Development Process

3.2 – Pre Production Process
3.3 – Bulk Production Process

Section 4 : Formats/Documents

Section 5 : Key Performance Indicators (KPIs) and Cockpit Charts

Section 6 : Process Audit Checklist

1.3 Objectives
1.3.1 Standardization of the mode of operating of technical processes in the garment manufacturing facilities across the group, hence to benchmark & continuously
improve the processes to achieve desired results.

1.3.2 To ensure effective and efficient planning of key resources deployed in the technical process such as manpower, machinery, material, space, etc, hence optimum
utilisation of the same throughout the facilities.

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1.3.3 Direct involvement in driving the style changeover time to the minimum possible level hence ensuring lost time/loss of productivity during the changeover process is
minimised.

1.3.4 To ensure pre production activities are carried out as per the company norms, hence enabling a smooth transition from current style to the new style and achieving
the bulletin targets as planned. Ultimately to ensure overall realisation of the pieces planned for the time period.
1.3.5 To improve the overall performance of garment on time delivery (OTD) by ensuring that the cutting process starts on time as per the time and action plan.

1.3.6 To ensure that the garments output from the sewing lines & finishing lines passes quality inspection right first time.

1.4 Glossary of the Terms Used

Term Description Term Description

SOP Standard Operating Procedure PP Pre Production

PR Person Responsible KPI Key Performance Indicator

BFM Basis for Measurement SMV Standard Minute Value

WIPCS Work in Progress Control System PPC Production Planning & Control

MD Managing Director CEO Chief Executive Officer

COO Chief Operating Officer CFO Chief Financial Officer

CPU Central Processing Unit CIMS Commerce Information Management System

CM Cut & Make CB Cost Breakdown

TNA, T&A Time & Action HOO Head Of Operation

WMS Warehouse Management System GRN Goods Received Note

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1.5 Process Map Symbols

Process Step Rework Connector Process Flow Direction Decision Box

1.6 Version Control History

SOP Serial Number SOP Code Version Description Date Reviewed & Approved By

12 TEC 1.1 Second Review June 2012 Managing Director, Epic Group

1.7 Periodicity of Review

1.7.1 Annually at the end of each financial year.

1.7.2 As and when processes are changed / amended.

1.8 Change Control

1.8.1 All suggestions for changes should be documented in the Change Control Form and sent to Managing Director – Epic Group for consideration for approval.

Section / Chapter Clause Ref. Existing Clause Suggested Clause Initiated by Authorised by

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 Section 2:
Standard Operating Procedures

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 2.1 Development Process

Serial # Process Activity PR Document #

Technical manager must participate in the initial style review meeting conducted by the sample department for a new
style before starting the sample process. Technical manager must study the style and suggest any operational
2.1.1 Head of Technical TEC001
changes required for the style for ease of production, whilst ensuring the buyer’s style specifications. If required
technical manager must submit mock-ups to enable customer to understand the required changes.

Technical manager must ensure the changes requested at the style review meeting which are approved by the
2.1.2 Head of Technical
customer is incorporated in the subsequent samples by reviewing the samples at the sample manufacturing stage.

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 2.2 Pre-Production

Serial # Process Activity PR Document #

Technical manager will receive a copy of the style changeover plan on 1st of every month for the next 3 months
2.2.1 Head of Technical TEC002
from the PPC department.

Technical manager will also receive the input control chart summary (next 45 days input) on 1st of every month for
2.2.2 Technical Manager TEC003
the next 3 months from the PPC department.

Technical manager will also receive the style changeover responsible personnel report from the IE department 4
2.2.3 Technical Manager TEC012
weeks prior to the 1st day of the following month.

Within 2 days of receipt of the above documents technical manager will prepare pilot run/PP meeting schedule for
technical department for the following two months. Immediately after preparation pilot run/PP meeting schedule, it
2.2.4 Head of Technical TEC004
will be circulated to the respective COO, HOO, unit head, merchandiser, head of sample & CAD, cutting manager,
maintenance manager & QC manager for their perusal.

Technical manger must analyze the pre-production sample requirement based on the prepared schedule to identify
2.2.5 any manpower/capacity issues and take necessary actions with the support of the COO/unit head to adjust the Head of Technical TEC004
capacity to cope up with the work load.

Technical manager must obtain the approved PP sample and a technical folder from merchandising before starting
2.2.6 Head of Technical
the pre-production sample process as per the schedule. i.e. 2 weeks prior to the sewing input date.

For stitching of the pilot run technical manager must prepare trims requisition slip based on the trim card received
2.2.7 Technical Manager TEC008
along with the technical folder and send to stores to obtain trims required for the pilot run.

Further technical manager must request adjusted PP patterns & embellishment placement boards (if applicable)
2.2.8 Technical Manager TEC005
from the sample room for the pilot run 2 weeks before the sewing input date.

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 2.2 Pre-Production (Continued…)

Serial # Process Activity PR Document #

Once the adjusted PP patterns are received from the sample room, 1 working day before the pilot run stitching date,
2.2.9 technical manager must ensure that the patterns are checked for the accuracy of the patterns. If patterns are Technical Manager TEC009
incorrect they must be returned to the CAD room for rework.

Technical manager must ensure that the embellishment placement boards are measured for the accuracy. If
2.2.10 embellishment placement boards are correct, same to be sent to the cutting. If incorrect they will be sent send back Technical Manager TEC005
to the sample & CAD room for rework.

In addition to the above items required for the pilot run, technical manager must request pilot cut from the cutting
2.2.11 department 2 weeks before the sewing input date. Cutting of the pilot samples must be done at the cutting Technical Manager
department.
It is the responsibility of the technical manager to ensure that the pilot cut markers are checked for the accuracy
before cutting the pilot run in the cutting department.

Pilot should consist of garments representing each colour in the order in full size range. If a colour has more than
2.2.12 one body pattern due to shrinkage, a full size range for each shrinkage pattern must be included in the pilot. Technical Manager TEC007

If there are 5 colours for an order, 6 sizes in the size range and 2 shrinkage ranges for each colour, pilot should
have total minimum pilot qty of 05 x 02 x 06 = 60 pieces.

If markers are accurate approval will be given to the cutting and if markers need reworking, technical manager will
2.2.13
inform the CAD room manager to make necessary adjustments.

Technical manager is responsible for checking the pilot cut immediately after cutting to verify the accuracy of the cut
2.2.14 panels. If the cut panels are not correct as per the buyer’s quality requirements, they will be returned to the cutting Technical Manager TEC007
department for rework.

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 2.2 Pre-Production (Continued…)

Serial # Process Activity PR Document #

Further technical manager will receive the tentative bulletin from IE dept. Upon receipt of the tentative bulletin
technical manager must ensure machines, folders, presser foots & attachments required for the pilot run are
prepared by the garment maintenance dept 1 working day prior to stitching the pilot run.

A manpower clarification chart must be filled for each pilot run with the operator name, ID number and the pilot Technical
operations each operator has to carry out. Manager/Unit
2.2.15 TEC013, TEC020
Maintenance
Technical manager must ensure that pilot line consists of operators who are not sample men but tailors who are
experienced from the floor. Manager

Further technical manager must ensure all pilot machines equipped with all the required folders / attachments /
guides as correctly used in the lines.

Once pilot run cut panels, actual trims & accessories are received, technical manager will instruct the technical
team to start stitching the pilot run. Technical TEC018, TEC010,
2.2.16 Manager/ QC TEC010A
It is the responsibility of the Technical manager to educate each pilot run operator on the machine operations to be
Manager
carried out and the expected quality requirement. Technical manager must monitor the performance of each pilot
operator during pilot production.

Pilot operator must be advised to record any technical difficulties faced during the manufacture of the pilot samples.
Further pilot operator must suggest easy production ideas or any attachment requirements which may help increase
the productivity, which were to be identified while the sample are being made. Technical
2.2.17
Manager
Technical manager must note all pilot operator comments and incorporate the suggestion in the pattern amendment
sheet to the CAD department, while giving the bulk cutting approval.

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 2.2 Pre-Production (Continued…)

Serial # Process Activity PR Document #

Once stitching is completed garments will be picked-up at random from the pilot run, 100% quality checking and
2.2.18 measurements checking of key measurements points will carried out by the technical team and the QC team.
Technical manager is responsible to rework garments if quality is not as per the expected standard by the buyer.

In case of non wash garments, garments to be finished as per the buyers specifications. 100% quality checking of Technical
2.2.19 the pilot run garments and measurement checking of key measurements points of the garments picked-up at Manager/ QC TEC010A
random will be carried out subsequently. Manager

In case garments needs processing in wet/dry/wrinkle free process (es),send pilot run garments to wet/dry/wrinkle
free process (es) for processing as per buyer's specifications. Upon receipt of the garments after processing in the Technical
2.2.20 TEC010, TEC011
respective areas, technical manager will instruct the technical team to conduct 100% quality checking of the Manager
garments and measurement checking of key measurements points of the garments picked-up at random.

Based on the pilot run results, pattern adjustments required for the bulk production should be sent to the CAD room.
Pilot run review meeting to be held with all concerned departments immediately after stitching and finishing. Pilot
run review meeting minutes prepared and shared with the meeting participants following the pilot run review Technical
2.2.21 meeting. TEC005, TEC018
Manager
Concerned departments to participate in the pilot run review meeting are production general manager, QC manager,
merchandising manager, maintenance manager, cutting manager, technical manager, finishing manager and CAD
room manager.

Subsequently, technical manager will call all concerned parties for the PP meeting. PP meeting to be held 1 week
prior to the sewing input date.
Concerned parties to attend the PP meeting are Head of Technical, Technical Manager, Unit Head, Production Technical
2.2.22
General Manager, Merchandising Manager, QC Manager, Audit Manager, IE Manager, Maintenance Manager, Manager
Head of Sample & CAD, Head of Washing & Wrinkle Free, QC Manager – Washing & Wrinkle Free, Fabric & Trims
Quality Manager and Stores Manager.

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 2.2 Pre-Production (Continued…)

Serial # Process Activity PR Document #

Conduct PP meeting & discuss, order details, buyer's special comments, all process details include technical,
quality, etc. Receive approved sample, approved shade band, internal fabric shade segregation report, colour wise Technical
2.2.23 garment cut plan, in-depth orientation of the buyer's standards and expectations of the garment from the respective TEC014
Manager
responsible department personnel.
Circulate PP review summary to the meeting participants within 2 working days of holding the meeting.

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 2.3 Bulk Production Process

Process Activity PR Document #

Technical
2.3.1 Technical manager must ensure that the bulk markers are checked and approved before bulk cutting. TEC007, TEC017
Manager

It is the responsibility of the technical manager to ensure the suitability of special m/c, folders, presser foots, jigs & Technical
2.3.2 attachments given by garment maintenance for bulk production before starting the bulk production.
Manager
Further technical manager is responsible for the preparation of templates & finished boards required for sewing.

Subsequently technical manager will receive the finalized and duly approved sewing operation bulletin, style Technical TEC013, TEC015,
2.3.3 changeover layout & line feeding plan from IE department, which will be used as the base documents in feeding the
Manager TEC016
new style.

Upon receipt of all documents mentioned above technical manager will start feeding line as per the bulletin, style
changeover layout, line feeding plan and the approved sample. Mock-ups required for all operations must be prepared Technical
2.3.4 TEC019
with the involvement of the quality department. Technical manager must ensure timely completion of the line feeding Manager
and also must ensure that quality pass garments are coming as output from the line.

First output garments from the line will be submitted to the technical manager by the line QC supervisor & technician
responsible for line feeding for first time approval. Technical team is responsible for 100% quality checking of the
garments along with the QC dept to ensure line output meets the buyer specified standards. Technical
2.3.5 If the garments meet buyer requirements, technical manager will grant approval to proceed with the bulk production. Manager/ QC
If issues are identified with the output, cutting, sewing, technical and quality teams must get together and make a Manager
team effort to resolve the issues at the earliest possible time to ensure that minimum amount of time is lost from the
process.

Technical manager is responsible to review the first bulk garments output from the finishing and issue final FTA to Technical
2.3.6 proceed with finishing of the bulk garments. A collective decision to be taken with the head of QA on the standard to
Manager
be approved as the FTA.

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 2.3 Bulk Production Process (Continued….)

Process Activity PR Document #

Technical manager is responsible to improve style ramp-up time & monitor IE build-up plan after feeding the line and Technical
2.3.7
troubleshoot day to day technical issues in the garment production. Manager

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 Section 3:
Process Map

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 Section 4:
Formats/Documents

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 TEC010A (Stationery)

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 Section 5:
Key Performance Indicators (KPIs) and
Cockpit Charts

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 Section 6:
Process Audit Checklist

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